Thrust Equalizing Mechanism for Cryogenic Turbine Generator

ABSTRACT

An improvement for a turbine generator or pump having main bearings separated by a span of shaft and a thrust equalizing mechanism adjacent one of said main bearings, the improvement comprising a stationary length compensator interposed between the thrust equalizing mechanism and its adjacent main bearing to reduce the span between said main bearings. Preferably the length compensator is composed of material that shrinks less than the shaft of the generator, and the height of the length compensator, i.e., the compensating dimension, is selected according to desired thrust equalizing mechanism operating parameters over a temperature range.

RELATED APPLICATIONS

This Application is a Divisional application of U.S. patent applicationSer. No. 12/794,649 filed Jun. 4, 2010, U.S. Pat. No. 8,513,847, to beissued Aug. 20, 2013, entitled “THRUST BALANCING DEVICE FOR CRYOGENICFLUID MACHINERY”, Attorney Docket No. EIC-402, which is aContinuation-In-Part application to U.S. patent application Ser. No.10/776,555 filed Feb. 10, 2004, entitled “THRUST BALANCING DEVICE FORCRYOGENIC FLUID MACHINERY”, Attorney Docket No. EIC-401, which isrelated to and a Non-Provisional application of U.S. Patent ApplicationNo. 60/446,460 filed Feb. 10, 2003, entitled “THRUST BALANCING DEVICEFOR CRYOGENIC FLUID MACHINERY”, Attorney Docket No. EIC-401-P, which areall incorporated herein by reference in their entirety, and claims anyand all benefits to which they are entitled therefrom.

FIELD OF THE INVENTION

The present invention relates in general to means and methods forbalancing the thrust felt by pumps and turbine generators operating in acryogenic environment, and in particular to a novel improvement in athrust balancing configuration to enhance the rotordynamic behavior ofvertical cryogenic pumps and turbine generators.

BACKGROUND OF THE INVENTION

The Liquid Natural Gas, hereafter “LNG”, production plants currently inthe design stages are utilizing economy of scale to increase productionwith lower capital costs, which has the effect of increasing the powerratings of the critical rotating equipment being supplied. As the powerrequirements increase with the demand for the next generation ofliquefaction plants, the generator size must increase physically. As thegenerator is the dominant component in terms of rotordynamic stability,the increased size has negative ramifications to the machinereliability. For example, higher power ratings of variable speedhydraulic turbine generators implicitly require larger physical sizes,but the possible loss of generator load demands critical speedseparation below continuous speed and above maximum “breakaway” speed.Furthermore, in the design of cryogenic turbine generators and pumps,there limitations on bearing size, shaft diameter and overall diameterof machines of this type. This invention presents a solution forincreasing the generator size, and power rating, while still maintainingacceptable rotordynamic characteristics.

For vertical cryogenic turbine generators, power increases of up to 10%can be achieved by reducing the span between the main bearings whichoffsets the reduction in the critical speed resulting from the increasedgenerator size. However this is not readily accomplished in machineshaving ball bearings which are cooled and lubricated by the productfluid. This is because the upper main bearing needs to be locatedoutside of the generator end turns to avoid any possible electricaleffects associated from the variable speed electrical control system ofthe generator, and the lower bearing is typically integral to a thrustbalancing system which is necessary due to the low viscosity ofliquefied hydrocarbon gases. The thrust balancing system is necessary toeliminate the thrust generated by the hydraulic components against thebearings in order to achieve adequate running time between overhauls.The TEMs (Thrust Equalizing Mechanism) mechanisms incorporated inmachinery designed by Ebara International Corporation, Sparks, Nev., aregood examples of such thrust balancing mechanisms which employ acombination of fixed and variable orifices, but there are limitationswith regards to location, length and resultant variable orifice gapsize. This invention provides a way for the lower bearing to be disposedcloser to the upper bearing, thereby reducing the gap therebetween,without interfering with the thrust balancing mechanism.

U.S. Pat. No. 3,104,553, patented Sep. 24, 1963 to Traeder et al.discloses a mechanical system arrangement for preventing repositioningor mass shift of the components in an assembly due to temperaturechanges. The patent does not describe hydraulic cryogenic machinerywhich is the subject the present invention.

U.S. Pat. No. 6,296,765, patented Mar. 8, 1988 to Brown discloses acomposite sleeve over a rotor hub with magnets. However, Brown is notrelated to hydraulic cryogenic machinery. In addition, Brown does notdescribe the magnetic coupling of the present invention which functionsto seal the rotor hub or motor/generator from the hydraulic portion.

U.S. Pat. No. 6,119,553, patented Sep. 19, 2000 to Yamagishi et al.discloses a rotation transmitting device that introduces rotation into avacuum side space via a flexible meshing type gear drive from anatmosphere side space. Yamagishi et al. is unrelated to hydraulicmachinery operated under cryogenic conditions and handling cryogenicliquids.

Other advantages and attributes of this invention will be readilydiscernable upon a reading of the text hereinafter.

SUMMARY OF INVENTION

An object of this invention is to provide a way for the lower bearing tobe disposed closer to the upper bearing, thereby reducing the gaptherebetween, without interfering with the functioning of a thrustbalancing mechanism.

A further object of this invention is to provide an improvement forreducing the span between main bearings to offset the reduction incritical speed resulting from increased machinery size.

These objects, and other objects expressed or implied in this document,are accomplished by a novel improvement for a turbine generator or pumphaving main bearings separated by a span of shaft and a thrustequalizing mechanism adjacent one of said main bearings, the improvementcomprising a stationary spacer interposed between the thrust equalizingmechanism and its adjacent main bearing to reduce the span between saidmain bearings. Preferably the spacer is composed of material thatshrinks less than the shaft of the generator, and the height of thespacer, i.e., the spacing dimension, is selected according to desiredthrust equalizing mechanism operating parameters over a temperaturerange. For a turbine generator or pump having main bearings separated bya span of shaft and a thrust equalizing mechanism which includes astationary thrust plate adjacent one of the main bearings and a variableorifice defined between the thrust plate and a throttle plate affixed tothe shaft, an improvement comprising a stationary length compensatorinterposed between the thrust plate and its adjacent main bearing tospace said adjacent main bearing from the thrust plate in order toreduce the span between said main bearings. Preferably the lengthcompensator is composed of material that shrinks less than the shaft ofthe generator, and the heights of the thrust plate and the lengthcompensator are selected to produce a desired variable orifice over arange of operating temperatures.

Benefits and features of the invention are made more apparent with thefollowing detailed description of a presently preferred embodimentthereof in connection with the accompanying drawings, wherein likereference numerals are applied to like elements.

In summary, the present invention is a turbine in combination with aTEM. While the turbine with TEM is previously described, the improvementis a turbine in combination with a TEM and in combination with a spacerbetween thrust plate and bearing. The inventive spacer is only appliedto hydraulic machines, pump or turbine, with thrust balancing orequalizing mechanisms. In the case of turbines, the inventive spacer isapplied to the design as an improvement to TEM technology, i.e., betweenthe bearing and thrust plate.

The TEM is associated with a sealless turbine generator mounted on asingle shaft compising a radial turbine having a unique thrustequalizing mechanism mounted thereto and operative with a portion of theapplied hydraulic fluid to the turbine radial runner and a thrustbearing for equalizing the generated thrust forces by providing a smallaxial, bidirectional movement of the thrust bearing and the elementsmounted on the single shaft and an induction generator driven by theturbine. The shaft along with the induction generator and the turbinecomponents except the turbine runner are isolated in a common housingand the entire assembly included in a submersible containment vesselhaving a fluid inlet and outlet for receiving the input hydraulic fluidflow at a preselected fluid pressure and velocity for controlling thespeed of the turbine. The induction generator includes a variablefrequency, exciting current source for the generator stator windingsthat permits changing the synchronous speed of the generator as requiredby the hydraulic fluid flow and hydraulic fluid head to permit theoverall efficiency of the turbine generator to be optimized. The turbinegenerator is operative with liquified gases that may be utilized tolubricate and cool the thrust bearing and the induction generator by thesmall portion of the operative fluid utilized for operating the thrustequalizing mechanism.

It will be appreciated that this hydraulic turbine operates in reversemode as a pump. All centrifugal pumps operated in reverse act as radialinflow turbines, and all radial inflow turbines operated in reverse actas centrifugal pumps. Similarly, electrical induction motors can beoperated as induction generators.

The present invention is an improvement of a hydraulic turbine generatoror pump, which is operable in cryogenic conditions. The presentinvention further consists of main bearings separated by a span of shaftand a thrust equalizing mechanism adjacent one of said main bearings, animprovement consists essentially of a stationary spacer interposedbetween the thrust equalizing mechanism and its adjacent main bearing toreduce the span between said main bearings. The improvement in which thespacer is composed of material that shrinks less than the shaft of thegenerator. Moreover, the improvement in which the height of the spaceris selected according to desired thrust equalizing mechanism operatingparameters over a temperature range. And the improvement in which theheight of the spacer is selected according to desired thrust equalizingmechanism operating parameters over a temperature range.

The present invention is also for a turbine generator or pump which hasmain bearings separated by a span of shaft and a thrust equalizingmechanism which includes a stationary thrust plate adjacent one of themain bearings and a variable orifice defined between the thrust plateand a throttle plate affixed to the shaft, an improvement which consistsessentially of a stationary length compensator interposed between thethrust plate and its adjacent main bearing to space said adjacent mainbearing from the thrust plate in order to reduce the span between saidmain bearings. The improvement in which the length compensator iscomposed of material that shrinks less than the shaft of the generator.Also, the improvement in which the heights of the thrust plate and thelength compensator are selected to produce a desired variable orificeover a range of operating temperatures. Moreover, the improvement inwhich the heights of the thrust plate and the length compensator areselected to produce a desired variable orifice over a range of operatingtemperatures.

The present invention is further a turbine generator or pump which hasmain bearings separated by a span of shaft and a thrust equalizingmechanism which further includes a stationary thrust plate adjacent oneof the main bearings, an improvement that consists essentially ofstationary means interposed between the thrust plate and its adjacentmain bearing to space said adjacent main bearing from the thrust platein order to reduce the span between said main bearings. And theimprovement in which the said means is composed of material that shrinksless than the shaft of the generator. Also, the improvement in which theheight of said means is selected according to desired thrust equalizingmechanism operating parameters over a temperature range. Moreover, theimprovement in which the height of said means is selected according todesired thrust equalizing mechanism operating parameters over atemperature range.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial cross-sectional view of a pump/turbine generator inthe vicinity of the lower main bearing and encompassing therunner/impeller of the prior art.

FIG. 2 is a more detailed view cut from FIG. 1 focusing on the thrustplate throttle ring interface.

FIG. 3 is a partial cross-sectional view of a pump/turbine generatoraccording to this invention focused in the vicinity of the lower mainbearing and encompassing the runner/impeller.

FIG. 4 is a more detailed view cut from FIG. 3 focusing on the thrustplate-throttle ring interface of the present invention.

FIG. 5 is a partial cross-sectional view of an aggressive fluid pump 500with a magnetic coupling 502 of the present invention.

FIG. 6 is a detail view of the thrust plate-throttle ring interface ofthe present invention.

FIG. 7 is a partial cross-sectional view of an alternative design of anaggressive fluid machine 500′ with a magnetic coupling 502 of thepresent invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The description that follows is presented to enable one skilled in theart to make and use the present invention, and is provided in thecontext of a particular application and its requirements. Variousmodifications to the disclosed embodiments will be apparent to thoseskilled in the art, and the general principals discussed below may beapplied to other embodiments and applications without departing from thescope and spirit of the invention. Therefore, the invention is notintended to be limited to the embodiments disclosed, but the inventionis to be given the largest possible scope which is consistent with theprincipals and features described herein.

Referring to FIGS. 1 and 2, a prior art machine with a conventionalthrust equalizing mechanism, hereafter “TEM”, is illustrated to have ahousing 2, a shaft 4, a lower bearing 6, a stationary thrust plate 8, athrottle ring 10 affixed to the shaft 4, a runner 12, a gap 14 above thelower bearing which allows the shaft 4 (and the bearing 6 and throttlering 10) to rise in response to any unbalance thrust from below, a fixedorifice 16 which communicates product fluid to a chamber 18 disposedabove the throttle ring, a variable orifice 20 defined between thrustplate 8 and the throttle ring 10, an upper wearing ring 22, and a lowerwearing ring 24. The operation of the thrust equalizing mechanism issimple. The upper wearing ring 22 is larger in diameter than the lowerwearing ring 24 resulting in a net resultant force in the upperdirection. Due to this upward force, the shaft 4, and all its rotatingcomponents move upward, the upward movement of the throttle ring 10reducing the variable orifice 20 between it and the thrust plate 8, thusrestricting the wearing ring leakage flow and causing the pressure inthe chamber 18 to increase. Due to increased pressure in the chamber 18,the thrust is reversed and now acts in a downward direction. This causesthe rotating assembly to move downward, thereby opening the variableorifice allowing the pressure in the chamber 18 to decrease. Theoperation vacillates back and forth automatically adjusting the pressurein chamber 18 sufficient to offset the upward thrust. Continuousself-adjustment allows the product-lubricated ball lower bearing 6 tooperate essentially at zero thrust load over the entire usable capacityrange. This feature substantially increases the reliability of thebearings, and reduces equipment maintenance requirements.

As explained above, it is desirable to reduce the span between the uppermain bearing 506 (NOT SHOWN) and lower bearing 6 in order to offset thereduction in the critical speed resulting from an increased generator ormotor size. However, relocating the lower bearing 6 by the requisiteamount would entail a dramatic increase in the length of the thrustbalancing device, and the resultant differential shrink between thethrust plate 8 material and the shaft 4 would cause the variable orificegap 20 to increase to such a degree that the thrust equalizing devicewould be rendered inoperable. Referring to FIGS. 3 and 4, the solutionto this problem is to integrate another component, a length compensatoror spacer 26, within the device composed of a material that shrinks lessthan the shaft 4. The spacer 26 is interposed between the bearing block28 and the thrust plate 8 to space the lower bearing 6 higher, i.e.closer to the upper main bearing 506 (NOT SHOWN). In one embodiment,spacer 26 is composed of material that possesses less than 1% of thermallinear contraction and spacer 26 should shrink less than shaft 4.Moreover, the height of spacer 26 is selected such that it is operativebetween 70 K and 140 K, the operating temperature range of the cryogenicliquid machinery. According to this invention, the individual heights ofthe thrust plate 8 and spacer 26 are selected to produce the desiredvariable orifice gap 20 at the actual operating temperature that willresult in the most effective thrust balancing and highest machineefficiency.

FIG. 5 is a partial cross-sectional view of an aggressive fluidpump/turbine 500 with a magnetic coupling 502. FIG. 6 is a more detailedview cut from FIG. 5 focusing on the thrust plat-throttle ringinterface. FIG. 7 is a partial cross-sectional view of an alternativedesign of an aggressive fluid hydraulic machine 500′ with a magneticcoupling 502. FIG. 5 shows an alternative of the present invention thatis designed for aggressive fluid such as LNG, ammonia, or otherflammable or explosive liquefied gases. As best shown in FIG. 5, sinceeither a motor or generator cannot be submerged in the processaggressive fluid as the configuration in FIGS. 3 and 4, an additionalmagnetic coupling 502 is installed and sealed between the TEM hydraulicmachinery 512 to said generator/motor 508. The main function of magneticcoupling 502 is to seal generator/motor 508 from process liquid and moreimportantly to transfer torque from the TEM hydraulic machinery 512 tosaid generator/motor 508. Hence separating generator/motor 508 from theprocess fluid. In one embodiment, TEM hydraulic machinery 512 andgenerator/motor 508 have separate shaft 4 and 510 respectively. As bestshown in FIG. 6, an alternative design of spacer 502 is placed withinthe device interposed between the bearing block 28 and the thrust plate8 to space the lower bearing 6 higher. In one embodiment, spacer 502composed of a material that shrinks less than the shaft 4.

As shown in FIG. 7, the TEM hydraulic machinery 512 with magneticcoupling 502 of the present invention can not only can processaggressive fluids, but is capable of connecting to any other piece ofrotary machinery or equipment such as, but not limited to, electricgenerators, motors, compressors, oil brakes, and other hydraulicsystems. Thus, a magnetic coupling 502 can be used to couple to theshaft 520 of essentially any rotatory type equipment or machine, such asother hydraulics, generator, motor, etc.

Use of the spacer concept in equipment handling ammonia or otheraggressive fluid design, the motor cannot be submerged in the processfluid, so a magnetic coupling 204 is employed to transfer the torquefrom the hydraulics to the motor, or in the case of an expander from thehydraulics to the generator. As stated above, this design does not haveto be connected to a motor or generator, but it can alternatively beconnected to some other rotating equipment or hydraulics.

The foregoing description and drawings were given for illustrativepurposes only, it being understood that the invention is not limited tothe embodiments disclosed, but is intended to embrace any and allalternatives, equivalents, modifications and rearrangements of elementsfalling within the reasonable scope of the claims which follow herein.

This Application is related to and an improvement over U.S. Pat. No.5,659,205, issued Aug. 19, 1997, entitled “HYDRAULIC TURBINE POWERGENERATOR INCORPORATING AXIAL THRUST EQUALIZATION MEANS”, which isincorporated herein by reference in its entirety. The above TEM patentteaches an improved hydraulic turbine electrical power generator that isoperable as a submerged hydraulic turbine electrical power generatorthat has a long life, seal-less, submerged turbine generator thatfunctions very well and may be readily adjusted for optimum efficiencyin operation and includes a self-limiting runaway speed by balancing outthe pressures generated by the centrifugal forces in the turbine againstthe input hydraulic fluid flow pressure. This later feature is veryimportant for submerged turbine generators due to the fact there is noway to stop the turbine in the event it reaches runaway speeds. Theturbine is further provided with a unique thrust equalizing mechanismutilizing a portion of the input fluid flow to balance the generatedthrust forces as well as utilizing the portion of the input fluid flowto lubricate the ball bearing for the turbine and cooling the electricpower generator.

The thrust equalizing mechanism for the turbine utilizes the prior artthrust equalizing mechanism (TEM) developed by G. L. Weisser forsubmersible pumps for cryogenic liquids and adapted for use in a turbineby mounting the ball bearing to traverse small, bidirectional movementsof the shaft assembly for balancing out the generated thrust forces.

The preferable orientation of the hydraulic turbine generator is in avertical orientation to achieve one hundred percent balancing of allforces whereby the overall efficiency of the turbine generator isoptimized. The pump and turbine of the present invention has a verticalorientation, i.e., a vertical rotational axis with predominantlyvertical flow through the machine, as distinguished from prior art pumpswith horizontal rotational axis and vertical flow. While flow of liquidwithin the vertical orientation pump and turbine passes from stage tostage, flow through the vertical pump or turbine is predominantly upwardor vertical, as shown in FIGS. 3-7.

The electric power generator is preferably in the form of an inductiongenerator having a rotor and a stator exciting winding controllable toprovide varying synchronous speeds for the generator and thereby permitsthe frequency of the exciting current for the generator to be uniquelyvaried to produce a preselected output frequency from the generatordespite the variations of the input hydraulic fluid pressure and flow aswell as varying the pressures generated by the centrifugal forces of theturbine without resorting to the use of adjustable guide vane assembliesor the like for the turbine runners. The hydraulic turbine generator isassembled on a single shaft mounted between a pair of ball bearingwithout any dynamic seals between the turbine generator and theenvironment.

From a structural standpoint, the TEM of the present inventioncomprehends a single shaft assembly having a hydraulic turbine and anelectrical power generator in the form of an electrical inductiongenerator mounted on opposite sides of a ball bearing with a radialbearing mounted to one end of the shaft on the outside of the electricalpower generator. The power generator has a rotor mounted to be rotatablewith the shaft rotations and axially movable therewith and arranged witha stator having an exciting electrical winding that is excitable from anA.C. source providing electrical signals of varying frequencies forvarying the synchronous speed of the power generator as required by theflow and head of the input hydraulic turbine that produce variablespeeds to produce a constant frequency output from the generator.

The hydraulic turbine is a radial turbine having the thrust equalizingmechanism operable with the turbine radial thrust equalizing runner forbalancing out the thrust forces through the small axial, bidirectionalmovements designed into the single shaft and ball bearing therefore.

The present invention is directed to equipment and machinery used inprocessing and handling aggressive fluids such as ammonia, LNG, or otherflammable or explosive liquefied gases.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the present invention belongs. Although any methods andmaterials similar or equivalent to those described can be used in thepractice or testing of the present invention, the preferred methods andmaterials are now described. All publications and patent documentsreferenced in the present invention are incorporated herein byreference.

While the principles of the invention have been made clear inillustrative embodiments, there will be immediately obvious to thoseskilled in the art many modifications of structure, arrangement,proportions, the elements, materials, and components used in thepractice of the invention, and otherwise, which are particularly adaptedto specific environments and operative requirements without departingfrom those principles. The appended claims are intended to cover andembrace any and all such modifications, with the limits only of the truepurview, spirit and scope of the invention.

I claim:
 1. A thrust equalizing mechanism for use with a hydraulicturbine-electrical power generator in a vertical orientation withvertical rotational axis mounted on a single shaft as a shaft assemblyand a ball bearing mounted intermediate the turbine and power generatorin a common housing except the turbine runner is mounted on the shaftoutside the common housing adjacent the ball bearing, and a containmentvessel enclosing the common housing and the shaft in a spacedrelationship therewith, said ball bearing having an inner race securedto said shaft and an outer race loosely mounted against the commonhousing with a bearing clearance for permitting the shaft to moveaxially, bidirectionally, a predetermined axial distance, said thrustequalizing mechanism comprising a stationary thrust plate ring meansmounted to said housing between the housing and said turbine runner,said runner means including throttling ring means constructed anddefined integrally with said runner means on one side thereof forcoaction with the thrust plate ring means for defining a substantiallyfixed orifice for receiving a portion of a high velocity hydraulicturbine flow coupled to impinge on said runner means and a variableorifice defined between the throttling ring means and the thrust platemeans and varying in size in accord with said movements of said shaftand receiving the hydraulic fluids at said variable orifice from saidfixed orifice, said variable orifice opening being initially greaterthan said fixed orifice opening, the arrangement and construction of thevariable orifice and said thrust plate ring means permits the hydraulicfluid to be conveyed through said ball bearing and through said commonhousing, said thrust equalizing mechanism further including first ringwear means secured to said common housing and spaced from saidthrottling ring means and second wear ring means secured to saidcontainment vessel adjacent said fluid discharge end of said runnermeans, the arrangement and construction of the diametrical spacing ofsaid first wear ring means is defined to be larger than the diametricalspacing of said second wear ring means for creating thrust forceseffective to cause the shaft assembly to move axially in the directionof the thrust forces until said thrust plate ring means engages saidthrottling ring means whereby the variable orifice is closed therebythrottling the hydraulic fluid flow into the variable orifice, saidclosed condition of said variable orifice defines a chamber between saidfirst ring means and the closed variable orifice allowing fluid pressureto build up therein so when the pressure is build up in said chamber toa preselected level for offsetting the thrust forces created and leadingto a movement of said shaft assembly away from said fluid throttlingcondition and thereby resulting in a continuous fluid flow into thevariable orifice and the reduction of the pressure built up in saidchamber whereby the balancing of the generated thrust forces occurgradually and smoothly and without overshoot with the continuousbidirectional, alternate axial movements of the shaft assembly, conduitmeans coupled to said housing for conveying said portion of the fluid inthe housing to adjacent the fluid discharge side of said runner means;and a stationary spacer composed of material having low thermal linearcontraction such that the stationary spacer shrinks less than the shaftof the generator interposed between the thrust plate and the bearingblocks of its adjacent main bearing to reduce the span between said mainbearings, the height of the spacer selected such that it is operativebetween 70 K and 140 K, the operating temperature range of the cryogenicliquid turbine generator.
 2. The thrust equalizing mechanism for usewith a hydraulic turbine-electrical power generator as defined in claim1 wherein said predetermined axial distance of movement of said shaftassembly due to said bearing clearance is approximately the same as thedistance of said variable orifice between said throttling ring andthrust plate ring means.
 3. The thrust equalizing mechanism for use witha hydraulic turbine-electrical power generator as defined in claim 1wherein said shaft assembly is mounted in a vertical orientation forbalancing out all of the forces.
 4. The thrust equalizing mechanism foruse with a hydraulic turbine-electrical power generator as defined inclaim 1 wherein said spacer composed of material having less than 1%linear contraction.